Front Brake Caliper Piston, Removing And Installing: Installing

-- The surface of the piston and seal must only be cleaned with mineral spirits or commercially available and then dried.

-- Thinly coat piston and seal with assembly paste before inserting.

-- Insert inner seal in brake caliper groove using trim removal wedge 3409.

-- Press in the protective cap using special tool -1- and -2-.

Fig 1: Pressing In Protective Cap Using Special Tool

Courtesy of AUDI OF AMERICA, LLC

-- Item -1- Piston Resetting Tool - Cap 5 T10146/5

-- Item -2- Piston Resetting Tool T10145

Use protective backings

-- Press the protective cap onto the brake caliper housing so that it contacts the brake caliper housing all around -arrow-.

Fig 2: Pressing Protective Cap Onto Brake Caliper Housing So That It Contacts Brake Caliper Housing

Courtesy of AUDI OF AMERICA, LLC

Use protective backings

-- It should no longer be possible to remove the protective cap from the brake caliper housing by hand.

Fig 3: Inserting Piston And Seal

Courtesy of AUDI OF AMERICA, LLC

-- Thinly coat piston and seal with Assembly Paste G 052 150 A2 before inserting.

-- Lift the brake piston, as shown, with commercially available extension and ratchet adapter and lightly press against the protective cap.

Fig 4: Lifting Brake Piston With Commercially Available Extension And Ratchet Adapter And Lightly Press Against Protective Cap

Courtesy of AUDI OF AMERICA, LLC

Do not tilt the piston in order to avoid damaging the sealing boot.

-- Blow the protective cap on with pressurized air (max. 3 bar (44 psi)). The protective cap will thereby jump over the brake piston.

Use protective backings

-- Press piston into the brake caliper housing by hand.

Fig 5: Pressing Piston Into Brake Caliper Housing By Hand

Courtesy of AUDI OF AMERICA, LLC

Install the brake caliper. Refer to BRAKE CALIPER WITH BRAKE CARRIER, REMOVING AND INSTALLING .